Angled and pre-stressed clip for retaining a bearing cup in a universal joint assembly

ABSTRACT

A universal joint assembly which prevents the bearing cups from rotating relative to the end yokes during use. In a first embodiment, the arms of a half round end yoke are formed having integral tabs which extend over the recessed areas of the associated bearing cups. The tabs cooperate with the shoulders to prevent the bearing cups from rotating relative to the end yoke. In a second embodiment of the half round end yoke, retainer straps extending about the outer circumferential surface of the bearing cups are provided with integral flanges. The retainer strap flanges cooperate with the bearing cup shoulders in the same manner as the tabs to prevent relative rotation. In a third embodiment, the bearing cups are disposed in openings formed in the arms of a full round end yoke. A retainer strap has end portions which are formed at a slight angle relative to the central portion. In a fourth embodiment, the retainer straps are secured to the full round end yoke by spring clips.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of Ser. No. 07/696,229 filed May 6, 1991, now U.S. Pat. No. 5,376,051 issued Dec. 27, 1994.

BACKGROUND OF THE INVENTION

This invention relates in general to universal joints and in particular to an improved structure for restraining the bearing cups mounted on a universal joint cross from rotating relative to an end yoke connected thereto during use.

Universal joints are well known devices which provide a driving connection between two members adapted to rotate about non-aligned axes of rotation. Universal joints of this type are widely used between rotatable drive shafts in vehicle drive train systems. Typically, such universal joints include a cross having a central body portion with four trunnions extending outwardly therefrom. The trunnions are oriented in a single plane and extend at right angles relative to one another. A bearing cup is mounted on the end of each of the trunnions. Needle bearings or similar means are provided between each of the trunnions and its associated bearing cup to permit the bearing cup to rotate relative to the trunnion. One pair of opposed bearing cups is connected to a first end yoke secured to the first drive shaft, while the other pair of opposed bearing cups is connected to a second end yoke secured to the second drive shaft.

When the axes of rotation of the two drive shafts are not co-axially aligned during operation, the bearing cups rotate relative to the trunnions in an oscillating fashion so as to permit the driving connection. It is desirable that the bearing cups be fixed in position relative to the end yokes connected thereto such that no relative rotation occurs therebetween. Otherwise, wear will occur in the end yokes and the outer surfaces of the bearing cups, causing premature failure of the universal joint. Many structures are known for preventing relative rotation from occurring between the bearing cups and the end yokes. For example, it is known to weld plates onto the end surfaces of the bearing cups and to bolt such plates to the end yoke. However, this structure, as well as other anti-rotation structures known in the art, requires extra parts and additional labor to install, thus increasing the cost and complexity of the universal joint. Furthermore, such an arrangement does not readily accommodate stack-up tolerances caused by the assembly of the various components. Accordingly, it would be desirable to provide an improved universal joint with an anti-rotation structure which is simple and inexpensive to construct and assemble, and which readily accommodates such stack-up tolerances.

SUMMARY OF THE INVENTION

This invention relates to several improvements in a universal joint assembly which prevent the bearing cups from rotating relative to the end yokes during use. Each of the bearing cups includes a pair of recessed areas formed on the opposite sides of an end surface. Each of the recessed areas defines a chord-like shoulder. The bearing cups may be connected to either a half round end yoke or a full round end yoke. In a first embodiment of the half round end yoke, the arms of the end yoke are formed having integral tabs which extend over the recessed areas of the associated bearing cups. The tabs cooperate with the shoulders to prevent the bearing cups from rotating relative to the end yoke. In a second embodiment of the half round end yoke, retainer straps extending about the outer circumferential surface of the bearing cups are provided with integral flanges. The retainer strap flanges cooperate with the bearing cup shoulders in the same manner as the tabs to prevent relative rotation.

In the full round end yoke embodiments, a retainer strap is provided which extends across the end surface of each of the bearing cups. The retainer straps are formed having stepped portions which extend into the recessed areas of the bearing cups to prevent relative rotation. The locating surfaces on the arms and the bearing cups may or may not be co-planar. In a first embodiment of the full round yoke, the end portions of the straps are formed at a slight angle relative to the central portions. The end portions function like springs to take up any looseness caused by stack-up tolerances and to pre-load the threaded fasteners securing the retainer straps to the arms. In a second embodiment of the full round end yoke, the retainer straps are secured to the yoke by spring clips which provide a similar resilient function.

Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a first embodiment of a universal joint assembly adapted for use with a half round end yoke in accordance with this invention.

FIG. 2 is a plan view of the universal joint assembly illustrated in FIG. 1 shown assembled.

FIG. 3 is an exploded perspective view of a second embodiment of a universal joint assembly adapted for use with a half round end yoke in accordance with this invention.

FIG. 4 is a plan view of the universal joint assembly illustrated in FIG. 3 shown assembled.

FIG. 5 is a plan view of a third embodiment of a universal joint assembly adapted for use with a full round end yoke in accordance with this invention.

FIG. 6 is a sectional elevation view of the universal joint assembly illustrated in FIG. 5.

FIG. 7 is a side elevational view of the retainer strap illustrated in FIGS. 5 and 6 shown in an unstressed condition.

FIG. 8 is a sectional elevational view of a fourth embodiment of a universal joint assembly adapted for use with a full round end yoke in accordance with this invention.

FIG. 9 is a side elevational view of the spring washer illustrated in FIG. 8 shown in an unstressed condition.

FIG. 10 is a plan view of a fifth embodiment of a universal joint assembly adapted for use with a full round end yoke in accordance with this invention.

FIG. 11 is a sectional elevation view of the universal joint assembly illustrated in FIG. 10.

FIG. 12 is a top plan view of a modified version of a retainer clip adapted for use in the universal joint assembly of FIGS. 10 and 11.

FIG. 13 is a sectional elevational view of the modified retainer clip taken along line 13--13 of FIG. 12.

FIG. 14 is a sectional elevational view of the modified retainer clip taken along line 14--14 of FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, there is illustrated in FIG. 1 an exploded perspective view of a first embodiment of a universal joint assembly, indicated generally at 10, in accordance with this invention. The assembly 10 includes a conventional cross member 11 having four trunnions extending radially outwardly in a common plane at right angles relative to one another. A bearing cup, indicated generally at 12, is mounted on the end of each of the trunnions. Needle bearings (not shown) or similar bearing means are provided between each of the bearing cups 12 and its associated trunnion to permit relative rotation therebetween.

Each of the bearing cups 12 is formed generally in the shape of a hollow cylinder having an outer circumferential surface 13 and a closed end surface 14. Two recessed areas 15 are formed in each of the end surfaces 14. The recessed areas 15 are defined by parallel chord lines extending to the circumferential edges of the bearing cup 12, although they may be defined by curved lines as well. Shoulders 15a are defined between recessed areas 15 and the end surfaces 14 of the bearing cups 12.

The illustrated assembly 10 further includes a first embodiment of a half round end yoke 20. The end yoke 20 includes a pair of arms 21 and 22 having semi-cylindrical recesses 21a and 22a formed therein. A tab 23 is formed integrally with each of the yoke arms 21 and 22. The tabs 23 extend over the ends of the respective semi-cylindrical recesses 21a and 21b. When the cross 11 is assembled to the end yoke 20, two opposed bearing cups 12 are received in the recesses 21a and 22a, as shown in FIG. 2. The tabs 23 extend over one of the recessed areas 15 formed in the end surfaces 14 of the bearing cups 12. The tabs 23 engage the one of the shoulders 15a formed on such end surfaces 14 so as to prevent rotation of the bearing cups 12 relative to the associated arms 21 and 22 of the end yoke 20. The tabs 23 may be formed having generally flat end surfaces for contacting the shoulders 15a.

Means are provided for retaining the bearing cups 12 within the semi-cylindrical recesses 21a and 22a of the end yoke 20. As shown in FIGS. 1 and 2, such means includes a pair of retainer straps 24. The central portions of the retainer straps 24 extend around respective portions of the outer circumferential surfaces 13 of the bearing cups 12. The end portions of the retainer straps 24 are secured to the arms 21 and 22 by threaded fasteners 25. Although there is some frictional engagement between the bearing cups 12 and the arms 21 and 22, such frictional engagement is not, of itself, sufficient to prevent relative rotation therebetween under all conditions. Thus, the cooperation of the tabs 23 with the shoulders 15a is provided to prevent such relative rotation.

Referring now to FIGS. 3 and 4, there is illustrated a second embodiment of a universal joint assembly, indicated generally at 30, in accordance with this invention. The assembly 30 includes a conventional cross member 11 having bearing cups 12 mounted thereon, as described above in connection with FIGS. 1 and 2. The assembly 30 further includes a second embodiment of a half round end yoke 31. The end yoke 31 includes a pair of arms 32 and 33 having semi-cylindrical recesses 32a and 33a formed therein. When the cross 11 is assembled to the end yoke 31, two opposed bearing cups 12 are received in the recesses 32a and 33a, as shown in FIG. 4.

Means are provided for retaining the bearing cups 12 within the semi-cylindrical recesses 32a and 33a of the end yoke 31. As shown in FIGS. 3 and 4, such means includes a pair of retainer straps 34. The central portions of the retainer straps 34 are curved and extend around respective portions of the outer circumferential surfaces 13 of the bearing cups 12. The end portions of the retainer straps 34 are secured to the arms 32 and 33 by threaded fasteners 35. However, unlike the retainer straps 24 discussed above, each of the retainer straps 34 is provided with an integral flange 34a. The flanges 34a extend across portions of the curved central portions of the retainer straps 34, defining a plane which is perpendicular to the plane defined by the end portions. When the cross 11 is assembled to the end yoke 31, two opposed bearing cups 12 are received in the recesses 32a and 33a, as shown in FIG. 4. The flanges 34a extend over one of the recessed areas 15 formed in the end surfaces 14 of the bearing cups 12. The flanges 34a engage the one of the shoulders 15a formed on such end surfaces 14 so as to prevent rotation of the bearing cups 12 relative to the associated arms 32 and 33 of the end yoke 31.

The embodiments described and illustrated thus far relate to universal joint assemblies adapted for use with half round end yokes. However, this invention also relates to universal joint assemblies adapted for use with full round end yokes. Referring now to FIGS. 5 and 6, there is illustrated a third embodiment of a universal joint assembly, indicated generally at 40, in accordance with this invention. The assembly 40 includes a conventional cross member 11 having bearing cups 12 mounted thereon, as described above in connection with FIGS. 1 and 2. The assembly 40 further includes a full round end yoke 41. The end yoke 41 includes a pair of arms (only one arm 42 is illustrated) having cylindrical openings 42a formed therethrough. A machined upper surface 42b is formed about each of the openings 42a. When the cross 11 is assembled to the end yoke 41, two opposed bearing cups 12 are received in the openings 42a such that the recessed areas 15 lie in the same plane as the machined surfaces 42b of the arms 42, as shown in FIGS. 5 and 6.

Means are provided for retaining the bearing cups 12 within the cylindrical openings 42a of the end yoke 41. As shown in FIGS. 5 through 7, such means includes a pair of retainer straps, indicated generally at 43 (only one is illustrated). The retainer straps 43 extend over the end surfaces 14 and the recessed areas 15 of the bearing cups 12. Each of the retainer straps 43 includes a central portion 43a connected by transition portions 43b to end portions 43c. As best shown in FIGS. 6 and 7, the end portions 43c lie in a plane which is offset from the plane defined by the central portion 43a. Thus, the transition portions 43b define lower shoulders 43d between the central portion 43a and the two end portions 43c. Apertures 43e are formed through the end portions 43c to permit threaded fasteners 44 to connect the retainer straps 43 to the arm 42 of the end yoke 41.

When the cross 11 is assembled to the end yoke 41, two opposed bearing cups 12 are received in the openings 42a, as mentioned above. Then, the retainer straps 43 are secured to the arm 42 by the threaded fasteners 44. When so secured, the lower surface of the central portion 43a lies across the end surface 14 of the bearing cup 12, while the end portions 43c lie across the recessed areas 15, as shown in FIG. 6. Also, the lower shoulders 43d of the retainer straps 43 engage the shoulders 15a defined on the end surface 14 of the bearing cup 12. Such engagement prevents rotation of the bearing cups 12 relative to the associated arms 42 of the end yoke 41.

As shown in FIG. 7, the end portions 43c of the retainer strap 43 may be formed at an angle relative to the central portion 43a thereof. In other words, the planes defined by the end portions 43c are not parallel to the plane defined by the central portion 43a. As a result, when the retainer strap 43 is secured to the arm 42 of the end yoke 41, the end portions 43c are flexed somewhat to the parallel position illustrated in FIG. 6. This flexing of the end portions 43a is useful in preloading the threaded fasteners 44. The additional force which is required to flex the end portions 43c causes the threaded fasteners 44 to additionally engage the threads of the bores in the yoke arm 42 which they are engaged greater than if no force was required to flex the end portions 43c. Because of this additional frictional engagement, the likelihood of the threaded fasteners 44 becoming loose during operation is reduced.

The angled formation of the end portions 43c is also helpful in accommodating stack-up tolerances in the universal joint assembly 40. Such stack-up tolerances result when a number of components, each having its own tolerance variations, are assembled together. In extreme instances, the combined effect of the tolerance variations can cause undesirable looseness in the universal joint assembly 40. The spring-like actions of the angled end portions 43c exert pressure on the end surfaces 14 of the bearing cups 12, urging them toward the cross member 11. As a result, any looseness in the assembly 40 is eliminated.

Referring now to FIGS. 8 and 9, there is illustrated a fourth embodiment of a universal joint assembly, indicated generally at 50, in accordance with this invention. The assembly 50 is generally similar to the third embodiment of the assembly 40 discussed above, except that the recessed areas 15 of the end surface 14 of the bearing cups 12 are not co-planar with the machined surfaces 42b formed about the openings 42 of the arms 42 of the full round end yoke 41. To accommodate this, a modified retainer strap, indicated generally at 51, is provided. The retainer strap 51 includes a central portion 51a, a pair of intermediate portions 51b, and a pair of end portions 51c. A first pair of shoulders 51d is defined between the central portion 51 and the intermediate portions 51b, while a second pair of shoulders 51e is defined between each of the intermediate portions 51b and the end portions 51c connected thereto. The first shoulders 51d engage the shoulders 15a on the bearing cups 12 to prevent relative rotation, as described above. The second shoulders 51e accommodate the different planes defined by the machined surfaces 42b and the recessed areas 15.

The end portions 51c of the retainer straps 51 are secured to the arms 42 of the yoke 41 by threaded fasteners 44, as described above. The end portions 51c of the retainer straps 51 may be formed at an angle relative to the central portion 51a, as described above in connection with the retainer strap 43. Alternatively, a spring washer 52 may be used to preload the threaded fasteners 44 to prevent loosening thereof. The structure of one of the spring washers 52 is illustrated in FIG. 9. As shown therein, the spring washer 52 is formed having a slightly arcuate shape when relaxed. When the threaded fasteners 44 are tightened, the spring washers 52 are flexed somewhat to the flat orientation illustrated in FIG. 9. This flexing exerts the preloading force on the threaded fasteners 44 similar to the manner described above.

Referring now to FIGS. 10 and 11, there is illustrated a fifth embodiment of a universal joint assembly, indicated generally at 60, in accordance with this invention. The assembly 60 is generally similar to the fourth embodiment of the assembly 50 discussed above, except that the retainer strap 51 has been replaced by a retainer clip, indicated generally at 61. The retainer clip 61 includes a base portion 61a and an angled end portion 61b. The base portion 61a is secured to the arm 42 of the end yoke 41 by the threaded fastener 44. The angled end portion 61b extends over the recessed area 15 of the bearing cup 12. The edge of the end portion 61b engages the shoulder 15a. Because of its angled configuration, the retainer clip 61 functions in the same manner as the angled end portions 43c of the above-described retainer strap 43 to retain the threaded fastener 44 and to accommodate stack-up tolerances in the assembly 60. The retainer clip 61 can also be used in combination with a half round end yoke.

Referring now to FIGS. 12 through 14, there is illustrated an alternate design for a retainer clip, indicated generally at 70, adapted for use in the fifth embodiment of the universal joint assembly 60 in lieu of the retainer clip 61. The retainer clip 70 includes a base portion 71, a transition portion 72, and an end portion 73. The base portion 71 has a pair of openings 71a formed therethrough to permit it to be secured to the arm 42 of the end yoke 41 by a pair of threaded fasteners (not shown). The end portion 73 extends over the recessed area 15 of the bearing cup 12. The edge of the end portion 73 is curved, unlike the above-described retainer clip 61. Therefore, the edge of the end portion 73 of the retainer clip 70 may, but does not necessarily, engage the shoulder 15a formed on the bearing cup 12. As shown in FIGS. 13 and 14, the thickness of the transition portion 72 varies between a maximum near the center thereof and a minimum adjacent to the openings 71a. The retainer clip 70 functions in the same general manner as the retainer clip 61.

In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. 

What is claimed is:
 1. A universal joint assembly comprising:a yoke including an arm having an opening formed therethrough; a cross having an outwardly extending trunnion; a bearing cup rotatably mounted on the end of said trunnion, said bearing cup including an outer circumferential surface and an end surface, said bearing cup being disposed within said yoke arm opening; and a retainer clip including a base portion secured to said arm of said yoke and an end portion extending over a portion of said end surface of said bearing cup, said end portion being angled relative to said base portion prior to installation on said yoke, said end portion engaging said end surface of said bearing cup in a pre-stressed relationship to provide a spring force against said bearing cup which provides the sole retaining force to prevent axially outward movement of said bearing cup and thereby retain it within said yoke arm opening.
 2. The universal joint defined in claim 1 wherein said bearing cup includes a recessed area formed in said end surface defining a shoulder, and wherein said end portion of said retainer clip terminates in an edge extending into engagement with said shoulder defined on said bearing cup end surface to prevent rotation of said bearing cup relative to said yoke.
 3. The universal joint defined in claim 1 wherein said retainer clip includes a transition portion between said base portion and said end portion.
 4. The universal joint defined in claim 3, wherein said transition portion has the same thickness as said base portion and said end portion.
 5. The universal joint defined in claim 3 wherein said transition portion has a different thickness as said base portion and said end portion.
 6. A universal joint assembly comprising:a yoke including an arm having an opening formed therethrough, said yoke defining a surface; a cross having an outwardly extending trunnion; a bearing cup rotatably mounted on the end of said trunnion, said bearing cup including an outer circumferential surface, an end surface, and a recessed area formed in said end surface defining a shoulder, said bearing cup being disposed within said yoke arm opening, said yoke surface and said recessed area of said bearing cup defining planes which are not co-planar; and a retainer clip including a base portion secured to said arm of said yoke and extending over said surface thereof and an end portion, said end portion being angled relative to said base portion prior to installation on said yoke, said end portion extending over and engaging said recessed area of said bearing cup in a pre-stressed relationship to provide a spring force against said bearing cup which provides the sole retaining to prevent axially outward movement of said bearing cup and thereby retain it within said yoke arm opening, said base portion and said end portion defining planes which are not co-planar, said end portion terminating in an edge extending into engagement with said shoulder defined on said bearing cup end surface to prevent rotation of said bearing cup relative to said yoke.
 7. The universal joint defined in claim 6 wherein said retainer clip includes a transition portion between said base portion and said end portion.
 8. The universal joint defined in claim 7 wherein said transition portion has the same thickness as said base portion and said end portion.
 9. The universal joint defined in claim 7 wherein said transition portion has a different thickness as said base portion and said end portion. 